Berg Propulsion BCP 950 HDX-500 CPP System Operation & Service Manual

Description

Berg Propulsion BCP 950 HDX-500 CPP System Operation & Service Manual

This is the complete Operation & Service Manual for the Berg Propulsion controllable pitch propeller (CPP) system built around the BCP 950 propeller hub and HDX-500 oil distributor box. Issued by Berg Propulsion AB of Öckerö, Sweden under Order No. 5272 & 5273, this manual covers the CPP installation on vessels built at Nanjing Yatai Shipyard (New Bldg. No. YT-05-401/402). It is the same document supplied with the equipment and provides the full technical foundation for operating, servicing, and troubleshooting this specific CPP system.

File Details

• Manual Type: Operation & Service Manual
• Brand: Berg Propulsion
• Equipment: BCP 950 HDX-500 CPP System
• Order No.: 5272 & 5273
• Language: English
• Page Count: Approximately 295 pages
• File Format: PDF
• Publisher: Berg Propulsion AB, Öckerö, Sweden

Chapters Covered

• 1. Technical Specification — Propeller and hub data, tail shaft and intermediate shaft dimensions, hydraulic system pump and motor specifications
• 2. BCP and HDX Description — Propeller and shafting delivery and installation, hub design, oil pressure coupling type OMC mounting and dismounting, oil pipes in shaft and gear, OD box design and installation, lubrication and hydraulic oil recommendations, oil circulation system
• 3. Accessories — Sterntube seals (IHC Supreme type SG-380-C-D and STF-300), sterntube and sterntube bearing installation, BAC shaft earthing device, net cutter
• 4. Hydraulic System — Pitch control unit oil distributor, pressure oil system, propeller hub lubrication oil system, oil recommendations, emergency control and pitch blocking, hydraulic pumps, water sensor and flow switch, routine service
• 5. Remote Control System ERC3000 — General description and system configuration, bridge forward and aft panel operation, engine room controls, command transfer system, manoeuvring and combinator curve, backup control and pitch indication, load control system, parameter setting and fault diagnosis, clutch control and shaft speed indication
• 6. Supervising System — Propeller system alarm list and settings
• 7. Spare Parts — Ordering information and spare parts lists
• 8. Special Tools — Blade screw spanner, leading member spanner, OMC coupling mounting equipment, shaft nut spanner

This Berg Propulsion BCP 950 HDX-500 CPP system manual is a full-scope service reference that spans the mechanical propeller hub, the hydraulic pitch control system, the electronic remote control system (ERC3000), and the supporting accessories. It is organized so that a technician can move from general system description through to specific procedures — from mounting blades and filling hub oil through to calibrating lever positions and diagnosing fault codes on the PLC-based remote control system.

The technical specification chapter gives the core operating parameters for the BCP 950 propeller: 3100 mm diameter, Cu Ni Al bronze material, four blades, counter-clockwise rotation, 3000 kW rated power, and 220 RPM maximum shaft speed. The tail shaft and intermediate shaft dimensions are also listed. The hydraulic system section identifies the Denison PV15/PV38 pump arrangement, the VEM 3-phase 4-pole motor, and the calculated and working pressures.

The BCP and HDX description section is where the mechanical heart of the manual sits. It covers blade installation, propeller shaft installation, hub oil filling, locking of screws and plugs before launching, and checking correct blade mounting. The hub design is illustrated with a cross-sectional diagram identifying guide rings, seals, seal supports, hub cylinder, hub body, torque pins, guide blocks, and sliding bars. The OMC oil pressure coupling section gives step-by-step mounting and dismounting instructions including the critical drive-up procedure with injectors and hydraulic pump, marking line reference (20 mm from aft end of coupling), and pressure hold times. The oil pipe section explains the four-channel pipe assembly in the shaft — center channel, peripheral channels for pitch setting, and the lubrication oil return path — with torque tightening values for M16 and M20 connections.

The OD box section describes the HDX-500 oil distributor and cylinder arrangement, with design diagrams, pipe connection sizing (hose lengths of 1.5 m, pipe A/B 38S, pipe D 28L, pipe L 35L for HDX 500), and installation procedures split between yard and Berg representative responsibilities. The run-out check for the OD shaft is specified at 0.1 mm maximum at sealing areas.

The lubrication and hydraulic oil chapter recommends specific marine hydraulic oils (Shell Tellus Tx 32/46, Esso Univis N 32/46, Texaco Rando HDZ 32/46, BP HLP/SHF46, Castrol Hyspin AWH-M 32/46, Total/Elf Visga 32/46, FINA HYDRAN HVI 32/46, Mobil DTE 13M/15M) and notes that oils with a viscosity index of 140 or greater are acceptable. The oil circulation chapter explains the 1 l/min circulation flow, the gravity tank arrangement, and the moisture content logging that allows predictive maintenance planning.

The hydraulic system chapter covers the pitch control unit oil distributor, the pressure oil system with variable displacement axial piston pumps and pressure compensation, the manoeuvre valve arrangement with solenoid-operated 4-way valve and pressure relief valve, the propeller hub lubrication oil circuit with gravity tank, water saturation measurement, hub lubrication oil filter, shut-off valve, flow switch, and emergency control and pitch blocking (take-home device). The routine service section lists daily checks for filter blockage indicators, water saturation monitoring, and the log form for monthly reporting to Berg Propulsion.

The ERC3000 remote control system chapter is extensive and covers the PLC-based full follow-up electronic remote control system for propeller pitch and main engine speed. It includes system configuration diagrams, operation of bridge forward and aft panels, engine room control panel operation, command transfer system with lever alignment, manoeuvring and the combinator curve, backup control and pitch indication system, load control system overview and operation, additional functions (overload, constant RPM, auto-load reduction, auto stop/shutdown, shaft speed indication, electric shafting system, DP/joystick/VDR interface, Fi-Fi mode), system configuration and technical data, parameter setting and fault diagnosis with the MV4 display unit, and clutch control and shaft speed indication.

The parameter setting section is particularly detailed, covering navigation through the display menus, examples for changing parameters (calibrating bridge lever signal, adjusting zero pitch), the parameter store function, password levels (operator, service), and fault diagnosis with error codes. This section gives the technician the ability to calibrate lever positions, set combinator curves, adjust delay programs, configure load control parameters, and interpret PLC error codes.

The accessories chapter includes the IHC Supreme sterntube seal manual for the aft seal (type SG-380-C-D) and forward seal (type STF-300). It covers installation, putting into operation, maintenance and repairs, with detailed instructions for alignment checks, built-in length verification, run-out measurement, zero wear down measurement, and overhaul procedures including liner machining and lip seal spring shortening. The sterntube and sterntube bearing section covers bearing dismounting and mounting, chockfast installation, and temperature sensor installation. The BAC shaft earthing device manual covers the silver alloy slip ring, brush holders, grounding plate, and monitoring box with millivoltmeter and alarm output.

The supervising system chapter provides a propeller system alarm list with identifiers SS01 through SS37 covering auto-start pump functions, hydraulic system pressure, hydraulic oil temperature, hydraulic tank oil level, gravity tank levels, aft sterntube bearing temperature, remote control system failures, and main/backup power failures. Each alarm entry includes the operating condition, alarm level, signal type, range, and remarks on delay settings.

The spare parts chapter explains the ordering procedure and lists filter inserts. The special tools chapter lists the blade screw spanner, leading member spanner, OMC coupling mounting equipment, and shaft nut spanner.

What This Manual Helps You Do

• Install and mount the BCP 950 propeller blades and hub assembly
• Mount and dismount the OMC oil pressure coupling with correct drive-up procedure
• Install and align the HDX-500 OD box, oil pipes, and pipe connections
• Fill, drain, and maintain hub lubrication and hydraulic oil
• Diagnose and adjust the hydraulic pitch control system
• Operate and configure the ERC3000 remote control system from bridge and engine room
• Calibrate lever positions, pitch feedback, and combinator curves
• Interpret PLC error codes and alarm lists
• Service sterntube seals, sterntube bearings, and shaft earthing devices
• Understand the propeller system alarm settings and monitoring points

Whether you are commissioning a new CPP installation, troubleshooting a pitch control fault, or planning a dry-docking service, this manual provides the procedures, specifications, and system knowledge required. The combination of mechanical assembly data, hydraulic schematics, electrical wiring diagrams, PLC parameter tables, and alarm lists makes it a complete technical reference for the Berg Propulsion BCP 950 HDX-500 CPP system.

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